Shaped beam suspended ceiling

ABSTRACT

A suspended ceiling system including shaped beams coupled to connecting blocks that enable a variety of geometric configurations of tiles. The beams may appear to be structural members of an ornate fixed ceiling in a building, and may have any desirable cross sectional shape such as a V, a U, or other custom shape. The beams also include ledges for supporting tiles. The connecting blocks are suspended from the fixed ceiling or other structure and include a plurality of beam interface surfaces that couple to the beams. The connecting blocks may have any desirable cross sectional shape to provide a desired number and geometric arrangement of beam interface surfaces, so that the beams form a desired geometric configuration such as a triangle, square, a pentagon, a hexagon and the like. Tiles are cut to match the geometric configuration and placed on the ledges of the beams.

CROSS-REFERENCE TO RELATED APPLICATIONS

This utility application claims the benefit of U.S. Provisional Patent Application 60/575,140 filed May 27, 2004; the contents of which is hereby incorporated by reference.

FIELD OF THE INVENTION

The present invention is directed to a suspended ceiling system, and more specifically to a support system for a suspended ceiling.

BACKGROUND OF THE INVENTION

Conventional suspended ceilings typically comprise metal rails and foam tiles, which are often installed in offices. These suspended ceilings carry the load of lightweight materials. Those who want suspended ceilings in their homes, apartments, luxury offices, or other buildings have few options for a “skilled craftsman” ceiling that will conform to the artistic taste or theme of such buildings.

In one option, wooden runners are suspended by wires from a fixed building structure. Lips of cross members rest in a groove of the wooden runners, such that the cross members are suspended by the lips. In another option, primary wooden rails that are shaped to longitudinally slide into a metal support member. A dove tailed slot of the wooden rails also longitudinally slides onto a dove tail shaped lower edge of a wooden insert that is within the metal support member. Thus, the wooden rails are supported by the wooden insert and the metal support member. A wire is run through a hole in the metal support member and through the wooden insert to suspend the wooden rails from a fixed building structure. Transverse secondary cross rails also comprise wooden rails that are shaped to longitudinally slide into a metal channel. The metal channel has a bent tab at each end, which are inserted into slots cut into the metal support members that support the primary wooden rail. Thus, the secondary cross rails are suspended by the bent tabs interfacing with the primary wooden rails. These options generally limit geometric configurations for the ceilings and are complex to install.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is an upward view of an exemplary ceiling embodiment;

FIG. 2 is three dimensional view of a shaped beam interfacing with a connecting block;

FIG. 3 is a top view of a shaped beam abutting a connecting block;

FIG. 4 shows a sectional view of a “V” shaped beam against a connecting block;

FIG. 5A illustrates an exemplary fastener for connecting a shaped beam to a connecting block;

FIG. 5B illustrates an exemplary cam that can be inserted into an access hole to lock the fastener in place;

FIG. 6 is a three dimensional view of an alternate shaped beam;

FIG. 7A is a three dimensional view of an alternate shaped connecting block;

FIG. 7B shows multiple tile configurations using triangular connecting block;

FIG. 8 is a three dimensional view of a pentagon connecting block connected to “V” shaped beam; and

FIG. 9 is a three dimensional view of a hexagon connecting block connected to “V” shaped beam.

DETAILED DESCRIPTION OF THE INVENTION

The present invention provides flexibility in ceiling design and supports more than lightweight tiles. Tiles comprised of sheet rock, wood, and/or other materials can be used with detailed beams to give a suspended ceiling a “solid” look and feel, yet retain functional access to the space above the ceiling. Shaped beams support the tiles and give more “body” to the framing by protruding from the ceiling.

FIG. 1 is an upward view of an exemplary ceiling embodiment 5. Shaped beams 10 are interconnected with connecting blocks 20 to create a grid. The grid comprises a set of shaped beams 10 of specified lengths running in a plane substantially parallel to a fixed ceiling (not shown). The shaped beams are connected by connecting blocks 20 at corners of a grid cell that is near the middle of the ceiling. Fewer connecting blocks 20 are needed for grid cells that have shaped beams interfacing with a wall or other edge. The grid can also comprise non-orthogonal configurations, such as triangles, hexagons, and the like, depending on the configuration of connecting blocks 20. Connecting blocks 20 are joined to shaped beams 10, which support loads from tiles 30 that rest on shaped beams 10. Shaped beams 10 can have any cross sectional shape for strength and/or aesthetic design. The shaped beams can be made of any material, including wood, plastic, metal, composites, and the like.

FIG. 2 is three dimensional view of a shaped beam 10 interfacing with a connecting block 20. Shaped beam 10 includes beam fastener holes, such as beam fastener holes 12 a and 12 b, which are generally bored through a surface of shaped beam 10 that interfaces with a connecting block, wall, and/or other support structure. Slots or other holes can be used, as alternatives. Fasteners (not shown) are placed within the beam fastener holes to attach shaped beam 10 to the support structures. Each beam fastener hole intersects an access hole, such as access hole 14 a, which enables a fastener to be inserted into the corresponding beam fastener hole. The access hole also provides tool access to a head of the fastener. A tool, such as an angled allen wrench (not shown), can be inserted into the access hole to drive the fastener along the beam fastener hole into an abutting support structure.

Corresponding block fastener holes, such as block fastener holes 22 a and 22 b are aligned with beam fastener holes, so that a shaped beam can be fastened to connecting block 20. Connecting block 20 can comprise a solid material into which the fasteners are driven. Alternatively, connecting block 20 can comprise a multi-piece structure, such as a rectangular box made of individual side pieces 24 a through 24 d. Beam interfaces surfaces of connecting block 20, such as beam interface surface 25 d, are generally shaped to interface with an end of shaped beam 10.

Connecting block 20 also includes suspension holes, such as suspension hole 26 a, for use in suspending connecting block 20 from a fixed ceiling 15 and/or other building structure. For example, a wire 40 can be run through one or more suspension holes and attached to fixed ceiling 15. Alternatively, or in addition, a hook, a strap, a bracket, a threaded shaft, and/or other suspension supports can be used to couple connecting blocks to building structures. A shaped beam can be used to conceal the support from view below the connecting block. A combination of connecting blocks and shaped beams support tiles that rest on ledges, such as ledge 16.

FIG. 3 is a top view of a shaped beam 10 b abutting connecting block 20. Beam fastener holes 12 c and 12 d align with block fastener holes 22 c and 22 d, so that a fastener can attach shaped beam 10 b to connecting block 20. Corresponding access holes 14 c and 14 d show where a tool can access the fasteners. Locations of other block fastener holes, such as block fastener holes 22 e and 22 f, illustrate where other shaped beams can be attached. Also shown are locations for suspension holes, such as suspension holes 26 a and 26 b.

FIG. 4 shows a cross sectional view of a “V” shaped beam 10 b against connecting block 20. The sectional view shows placements for fastener holes 12 c and 12 d relative to a cross section of shaped beam 10 b and connecting block 20. The sectional view also shows that access holes 14 c and 14 d need not go all the way through shaped beam 10 b. Instead, access holes 14 c and 14 d can be recessed so that visible surfaces 18 c and 18 d remain uniform in appearance. Suspension hole 26 b is also hidden from view by shaped beam 10 b. Tiles hide other elements by resting on ledges 16 c and 16 d.

FIG. 5A illustrates an exemplary fastener for connecting a shaped beam to a connecting block. The example fastener is a minifix connecting bolt 50, part number 262.28.610, produced by Hafele America Co. Minifix connecting bolt 50 includes a head 52 that is engaged with a tool to drive a threaded end 54 into connecting block 20. Many other types of fasteners can be used, such as confirmats, screws, bolts, friction pegs, and the like. FIG. 5B illustrates an exemplary cam that can be inserted into an access hole to lock the fastener in place. The example fastener is a minifix cam 56, part number 262.18.011, produced by Hafele America Co. Minifix cam 56 includes a cam portion 58 that engages the head of the fastener to prevent the fastener from loosening. Many other types of inserts can be used for the access holes, such as plastic caps, wood pegs, and the like.

FIG. 6 is a three dimensional view of an alternate shaped beam. A “U” shaped beam 60 is shown connected to a rectangular block 28. Many other beams can be used, including, semi-circular shaped beams, “W” shaped beams, or other custom shaped beams. The beams may be constructed with solid cross sections, assembled from multiple parts, and the like. The ends of the beams may also be tapered, curved, or otherwise formed to mate with a correspondingly formed connecting block. For example, the ends of “V” shaped beams may be cut at an angle, or otherwise formed to mate with beam interface surfaces of a connecting block that may be formed in the shape of an inverted pyramid with four beam interface surfaces that meet at a point directed downward toward a floor.

FIG. 7A is a three dimensional view of an alternate shaped connecting block. A triangular connecting block 70 has a triangular cross section. Triangular connecting block 70 is shown connected to “V” shaped beam 10. Triangular connecting block 70 enables alternate grid configurations of tiles. For example, FIG. 7B shows a hexagon tile configuration 72, a rectangular tile configuration 74, and a triangular tile 76 using triangular connecting block 70. Other grid configurations may be implemented with a single connecting block coupled to a central portion of a fixed ceiling, and coupling shaped beams between the connecting block and surrounding walls. Similarly, one or more connecting blocks can be coupled to a portion of the fixed ceiling, and shaped beams may be coupled between the connecting blocks and only one, or only some of the surrounding walls. In this way a portion of the fixed ceiling remains exposed, or may be covered with a different ceiling, by a light, or used to suspend other objects.

Some grid configurations are implemented by using beams with angled ends, such that a primary axis of some beams are not perpendicular to a face of the connecting block. Still other grid configurations can be implemented by fastening a connecting block to a longitudinal portion a beam, rather than to an end of the beam.

FIG. 8 is a three dimensional view of a pentagon connecting block 80 connected to “V” shaped beam 10. Pentagon connecting block 80 enables still other grid configurations, such as alternating triangular grids and rectangular grids. FIG. 9 is a three dimensional view of a hexagon connecting block 90 connected to “V” shaped beam 10. Hexagon connecting block 90 can also be used to create alternating grids, or uniform grids. For example, a grid configuration can alternate between triangles and hexagons. Alternatively, the grid configuration can comprise only hexagon tiles. As indicated above, many other grid configurations can be implemented with still other connecting block shapes, by using angled beam ends, and/or by fastening connecting blocks to longitudinal portions of the connecting blocks. Beams can also be used that are not primarily strait. For example, a curved beam, an “L” shaped beam, and/or other longitudinal shapes can be used in combination with connecting blocks of one or more shape.

The above specification, examples, and information provide a complete description of the manufacture and use of the composition of the invention. Since many embodiments of the invention can be made without departing from the spirit and scope of the invention, the invention resides in the claims hereinafter appended. 

1. A suspended ceiling system comprising; a shaped beam including a ledge for supporting a tile; and a connecting block for coupling to a fixed ceiling of a structure, wherein the connecting block includes a plurality of beam interface surfaces, each of which can be coupled to an end of the shaped beam.
 2. The suspended ceiling system of claim 1, further comprising a suspension support that attaches to the connecting block and to the fixed ceiling to suspend the connecting block from the fixed ceiling.
 3. The suspended ceiling system of claim 2, wherein the suspension support comprises one of the following: a wire, a bracket, and a threaded shaft.
 4. The suspended ceiling system of claim 1, wherein the shaped beam includes a beam fastener hole and the connecting block includes a block fastener hole that can be aligned with the beam fastener hole for coupling the shaped beam to the connecting block.
 5. The suspended ceiling system of claim 4, wherein the beam fastener hole intersects an access hole in the shaped beam for access to a fastener.
 6. The suspended ceiling system of claim 1, wherein the connecting block comprises one of the following: a single solid and a plurality of side pieces.
 7. The suspended ceiling system of claim 1, wherein the plurality of beam interface surfaces of the connecting block form a cross section of the connecting block into one of the following: a triangle, a square, a pentagon, and a hexagon.
 8. The suspended ceiling system of claim 1, wherein the shaped beam comprises a cross section of one of the following: a V, a U, a W, and a semicircle.
 9. The suspended ceiling system of claim 1, wherein at least one of the following: the shaped beam comprises a wood product; and the connecting block comprises a wood product.
 10. The suspended ceiling system of claim 1, further comprising a tile to be supported at least partially by the shaped beam.
 11. A suspended ceiling, comprising: a plurality of shaped beams, each including a ledge for supporting a tile; and a plurality of connecting blocks for suspension from a fixed ceiling of a structure, wherein each connecting block includes a plurality of beam interface surfaces for coupling to the plurality of shaped beams to form a geometric grid of shaped beams to support a geometric configuration of tiles.
 12. The suspended ceiling of claim 10, wherein the geometric grid comprises at least one of the following: a triangle, a square, a rectangle, and a hexagon.
 13. The suspended ceiling of claim 10, wherein a subset of the plurality of shaped beams are coupled to a wall.
 14. A method for forming a suspended ceiling system, comprising: providing a shaped beam to include a ledge for supporting a tile; and providing a connecting block for coupling to a fixed ceiling of a structure, wherein the connecting block includes a plurality of beam interface surfaces, each of which can be coupled to an end of the shaped beam.
 15. The method of claim 14, further comprising: coupling the connecting block to a fixed ceiling; and coupling an end of the shaped beam to one of the plurality of beam interface surfaces of the connecting block.
 16. The method of claim 15, further comprising: coupling an additional shaped beam to another one of the plurality of beam interface surfaces, wherein the additional shaped beam includes another ledge for supporting the tile; and placing a portion of the tile on the ledge of the shaped beam and another portion of the tile on the other ledge of the additional shaped beam.
 17. The method of claim 16, further comprising coupling an opposite end of the shaped beam to a support, wherein the support comprises one of the following: another connecting block and a wall.
 18. The method of claim 15, wherein the connecting block is coupled to the fixed ceiling with one of the following: a wire, a bracket, and a threaded shaft.
 19. The method of claim 15, wherein coupling the end of the shaped beam to one of the plurality of beam interface surfaces comprises: aligning a beam fastener hole in the shaped beam with a block fastener hole in the connecting block; and inserting a fastener through the beam fastening hole and the block fastener hole such that the fastener mates the end of the shaped beam to the one of the plurality of beam interface surfaces of the connecting block.
 20. The method of claim 15, further comprising: coupling a plurality of additional connecting blocks to the fixed ceiling, wherein each of the plurality of connecting blocks includes a plurality of beam interface surfaces; coupling a plurality of additional shaped beams to each of the plurality of connecting blocks, such that at least one of the plurality of additional shaped beams is coupled to the connecting block. 